Electro-hydraulic manifold assembly and method of making same for controlling de-activation of combustion chamber valves in a multicylinder engine

ABSTRACT

A solenoid valve and manifold assembly for installation on an engine and connecting with hydraulic circuits in the engine for de-actuating the combustion chamber valves of selected cylinders of the engine. A manifold deck is formed with the valving channels and ports therein for connecting to the hydraulic circuits. A gasket is formed with solenoid valve mounting bosses and valving passages as a unitary member and is retained on the manifold deck by a retaining plate preferably stamped from sheet stock with clearance holes received over the valve mounting bosses and secured to the manifold deck over the gasket for sealing the gasket thereon. The valves are inserted in the bosses and retained by a preferably stamped bracket and the bracket, retaining plate and gasket secured to the manifold deck by common fasteners. A common electrical lead frame is received over the valve terminals for making electrical connection to the valves. The assembly of valves and the manifold deck may then be attached to the engine as a unit.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to an electrically operated valveand manifold assembly for controlling flow of hydraulic fluid in acircuit for deactivating the hydraulic lash adjusters or valve liftersin an internal combustion engine. In certain multi-cylinder motorvehicle engine applications, it has been desired to deactivate thecombustion chamber valves of the engine for purposes of disablingcombustion in certain of the cylinders during light load or “lowthrottle” applications in order to increase efficiency, conserve fueland reduce the emissions from the engine combustion chambers. It hasalso been found that disabling the operation of some of the cylindersenables the remaining cylinders to operate at a higher throttle or loadcondition which reduces the air flow or “pumping” losses which wouldotherwise occur over a nearly closed air throttle.

[0002] Where the engine valves are operated from a camshaft, such as byhydraulic valve lifters or lash adjusters through direct action foroverhead cam arrangements or through intermediate linkages such asrocker arms, finger followers or push rods or other types of enginevalve gear arrangements, the valves may be left close by hydraulicallydisabling the valve lift function.

[0003] In such arrangements, an electrically operated valve opens a flowof hydraulic fluid, typically engine lubricant, through a separatechannel or circuit to cause hydraulic movement of the lash adjusters toa position preventing movement of the engine valves.

[0004] In engines where such valve de-actuation is employed, in order tosimplify the final assembly of the engine and installation of theelectric valves for de-actuating the valve lifters, it has been desiredto provide an assembly of a manifold and the valves for deactivatingrespectively the desired cylinder which may be mounted as a unit on theengine during engine buildup. Heretofore, such an arrangement hasrequired two separate manifold plates usually cast of aluminum materialwith subsequently machined surfaces formed on the castings in order toprovide the appropriate passages for valving the lubricant to the valvelifters and to provide a mounting arrangement for the individualelectric valves to connect to the respective hydraulic circuit and tofacilitate the manifold and valve assembly as a unit onto the engine.

[0005] Such a known arrangement is shown in FIG. 4 wherein the valve andmanifold assembly indicated generally at 1 includes an upper manifoldplate or deck 2 having a channel 3 formed therein which communicatesthrough an aperture 4 in a gasket 5 disposed over the undersurface ofthe deck 2. Gasket aperture 4 communicates with an inlet port 6 providedin a lower manifold plate or deck 7 which is adapted for connecting toan hydraulic circuit on the engine block (not shown). Channel 3communicates through a second aperture 8 formed in the gasket 5 whichaperture 8 communicates with a valving chamber 9 having an electricallyoperated valve 10 mounted on the lower deck 7 for valving flow fromchannel 3 to a channel 11 which supplies an outlet port (not shown) forthe respective valve to be de-actuated.

[0006] In operation, pressurized fluid is provided in a supply channel 3formed in the undersurface of upper deck 2 through inlet port 6 in thelower deck; and, the supply channel communicates through an aperture 8in the gasket to valving chamber 9. Upon energization, solenoid 10effects movement of a valve member 13 from its valve seat and permitsflow through the gasket aperture 12 which communicates with outletchannel 11 formed in the undersurface of the upper deck 2. Channel 11communicates with respective control pressure port apertures in thegasket (not shown) for de-actuating the respective engine valves andalso communicates through a flow limiting bypass gasket port 17 andbypass orifice 16.

[0007] A bleed orifice 16 is provided in the lower deck 7; and, orifice16 communicates with a bypass aperture 17 in gasket 5 which communicateswith the supply channel 11 to provide a highly restricted and limitedbleed flow to bypass the valve and return to an unshown sump. Anelectrical lead frame 9 is provided for electrical connection to thesolenoid 10.

[0008] The known arrangement shown in FIG. 4 has thus required twoseparately machined manifold decks or plates and has proven to beprohibitively costly and heavy for high volume production motor vehicleapplications.

[0009] Thus, it has been desired to provide a way or means of reducingthe weight and cost of the electric valve and hydraulic manifoldassembly for controlling the de-actuation of the combustion chambervalves in a multi-cylinder motor vehicle engine.

BRIEF SUMMARY OF THE INVENTION

[0010] The present invention provides a solution to the above-describedproblem and employs an electric valve and manifold assembly having anupper manifold plate with lubricant or hydraulic fluid passages thereinwhich has disposed over the underside thereof, with ports formed thereinfor communicating with the corresponding fluid passages and a gasketwhich has formed integrally thereon mounting surfaces forming a valvingchamber with the manifold deck and providing valve mounting cavities.Electrically operated valves are mounted directly on the gasket mountingcavities; and, the gasket is retained by a simple flat plate and thevalves retained on the gasket mounting cavities by a stamped bracketwhich is attached through the gasket to the manifold deck. The assemblyof the present invention thus eliminates the need for a separatesecondary or lower manifold deck having machined hydraulic passagestherein. The present invention reduces the overall cost and weight ofthe manifold assembly and simplifies the fabrication thereof yetpreserves the function of attaching a single unit to an engine foreffecting electrically controlled deactivation of the engine valvelifters.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a cross-section through one of the valves in theassembly of the present invention;

[0012]FIG. 2 is an exploded view of one of the electrically operatedvalves in a portion of the manifold assembly with the valve thereon;

[0013]FIGS. 3a and 3 b together comprise the complete exploded view ofthe valves and manifold subassembly of the present invention as embodiedfor selectively disabling the valves of four cylinders of an engine;

[0014]FIG. 4 is a section view similar to FIG. 1 of a Prior Art valveand manifold subassembly;

[0015]FIG. 5 is a bottom view of the manifold upper deck of thesubassembly of FIG. 1;

[0016]FIG. 6 is a perspective view of the underside of the upper decksealing gasket;

[0017]FIG. 7 is a perspective view of the top side of the upper decksealing gasket;

[0018]FIG. 8 is a perspective view of a portion of the entire manifoldsubassembly of FIGS. 3a and 3 b; and,

[0019]FIG. 9 is an enlarged view of a section taken alongsection-indicating lines 9-9 of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Referring to FIGS. 1 through 3 and 5 through 8, the manifold andvalve assembly of the present invention is indicated generally at 20 andincludes an upper deck 22 which has on the undersurface thereof a fluidsupply channel 24 which extends along the length thereof andcommunicates with four individual side channels 26 spaced therealong forsupplying hydraulic fluid from a port 25 which, upon installation of theassembly 20 into the vehicle engine, to a source (not shown) ofpressurized lubricant from the engine lubricating oil pump.

[0021] A combination gasket and valve mounting member 28 has formedthereon a plurality of valve mounting bosses 30, a typical one of whichis shown in cross section in FIG. 9, each of which has an aperture 32formed therethrough for communicating with the supply channel 24 and ableed orifice 34 which communicates with one of the side channels 26 forproviding bypass flow around the valve through an outlet port 36 whichcommunicates with a channel 38 formed in the undersurface of deck 22 andwhich each include a side channel 40. The enlarged opening port 35formed in the gasket for each of the bleed orifices 34 communicates withone of the inlet side channels 26. Each of the bosses 30 has a cavitytherein defining a valve mounting surface 33 for receiving a solenoidvalve sealingly engaged therein as will be later described.

[0022] In the presently preferred practice, the upper deck 22 is formedof cast aluminum material and the gasket 28 is formed of polyamidematerial fractionally filled with glass particulate; as, for example,one-third glass fill by volume, although other fractions of fill may beemployed, and other suitable engineered resinous materials besidespolyamide may be used.

[0023] Referring to FIGS. 1, 2 and 3 b, a solenoid operated valveindicated generally at 42 includes a moveable valve member in the formof a ball 44 which is registered against a valve seat 46 whichcommunicates with the inlet aperture 32 formed in the gasket 28. Thevalve seat 46 is formed in member 56 attached to the valve body 47 whichincludes a moveable armature 48 with a rod 50 contacting the ball member44 for effecting movement thereof and a coil 52 surrounding the armatureand a stationary pole piece 54. The valve seat is formed in a member 56attached to the valve body 47 and member 46 has a seal ring 58 disposedthereover for sealing in the aperture 32 in the gasket; and, a secondO-ring 60 is provided on the valve body for sealing in the boss 30.

[0024] The valve 42 includes electrical terminals 62 which extenddownwardly therefrom for external attachment thereto in a manner as willbe hereinafter described. The valve body 47 includes a pair of outwardlyextending lugs 64 for orienting and retaining the valve in the boss 30in a manner as will hereinafter be described.

[0025] Referring to FIG. 2, 3a, and 6 through 8, the gasket has a beadof suitable resilient sealing material provided around the periphery andthe ports thereof as denoted by reference numeral 66; and, in thepresently preferred practice of the invention the sealing materialcomprises silicone elastomer; however, it will be understood that othersealing materials may be employed.

[0026] Referring to FIGS. 2, 3a, and 6 through 8, the gasket 28 isregistered against the undersurface of deck 22 and is sealed andretained thereon by a retainer plate 68 which, in the presentlypreferred practice of the invention may be stamped from sheet stock andrequires no subsequent machining operations. The plate 68 has clearanceapertures 70 provided therein for permitting the solenoid operated valve42 to be inserted in the boss 30 through the aperture 70 in the plate.The lugs 64 engage slots 72 provided on opposite sides of each of theaperture 70 to orient the valve 42 such that the electrical terminals 62are aligned for subsequent simultaneous interconnection thereto.

[0027] Referring to FIGS. 1, 2, 3 b and 8, a valve retaining bracket 74with clearance apertures 76 provided therein is received over theretaining plate 68 with each of the apertures 76 received over one ofthe valves 42. The bracket 74 is preferably formed also by stamping fromsheet stock and has a pair of preferably integrally formed projections78 extending downwardly therefrom on opposite sides of the clearanceaperture 76. Each of the projections 78 engages one of the lugs 64 onthe valve 42 for retaining the valve in the boss 30 and seal rings 58,60 engaged in the inner surfaces of the boss into which the valve isassembled.

[0028] Referring to FIGS. 1, 2, 3 b, and 8, an electrical lead frame 80is commonly received over all of the solenoid valves 42 with theelectrical terminal 62 of each valve 42 engaged in an appropriatelylocated slot 82 provided on the lead frame in preferably bayonet-type orpush-on engagement. It will be understood that the lead frame 80 hasembedded therein appropriate electrical circuit conductors (not shown),portions of which are exposed (not shown) in each of the slots 82, suchthat the terminals 62 make electrical connection therewith upon theaforesaid bayonet engagement. The lead frame has an electrical connectorreceptacle 84 provided at one end thereof which has electrical pins (notshown) provided therein which are connected to the internal circuitconnector members of the lead frame in a manner well known in the art;and, upon attachment of a wiring harness connector (not shown) to thereceptacle 84, each of the solenoids may be controlled by an unshownremote controller.

[0029] The lead frame 80 has spaced stanchions 84 provided on the upperside thereof, each of which is located over cut outs provided in theedge of bracket 74 and the retaining plate 68; and, apertures areprovided in the gasket 28 and the upper deck 22 such that suitablefasteners such as screws 86 (see FIG. 3a) may engage the end of thestanchions 84 in threaded engagement to retain the lead frame 80securely attached to the valve electrical terminals.

[0030] It will be understood that the bracket 74, retaining plate 68,gasket 28 and deck plate 22 are retained together by fasteners such asscrews 88 received through appropriately located apertures formed in thebracket 74, retaining plate 68, with the screws 88 threadedly engagingthe upper deck 22.

[0031] Referring to FIG. 3a, the upper deck 22 has a boss 90 providedthereon which has provided therethrough a filling passage 92 whichcommunicates through aperture 94 in gasket 28, a correspondingly locatedaperture 96 in retaining plate 68 and aperture 98 in bracket 74. Ifdesired, a filter 104, shown in dashed outline, may be inserted in port92. A correspondingly located filling passage (not shown) is provided inthe engine structure onto which the manifold subassembly is mounted, asfor example, by a correspondingly located stanchion provided on theengine.

[0032] The boss 90, has a removable cap 100 provided on a fitting 102which is attached to the boss 30.

[0033] Upon installation of the manifold subassembly 20 onto the enginethe valve lifter de-actuation circuit is filled through the fitting 90and port 92. Cap 102 is installed on fitting 90 to seal port 92.

[0034] The completed subassembly 20 is retained on the engine bysuitable fasteners 106 received through apertures formed in the manifoldupper deck 22, and cut outs formed in the edges of gasket 28, retainingplate 68 and bracket 74. Fasteners 106 then make threaded engagementwith appropriately tapped holes (not shown), the engine block structure(not shown).

[0035] The present invention thus provides a novel, low cost andeasy-to-fabricate and install manifold and valve assembly for an enginehydraulic valve lifter deactivation function. The valve and manifoldassembly of the present invention requires only a single manifold deckwhich may be cast and provides for mounting of the valves directly onmounting bosses formed on the gasket, which is retained and sealed ontoby a simple stamped retaining plate. The present invention thuseliminates the need for a second manifold deck and the complexity,weight and cost thereof.

[0036] Although the invention has hereinabove been described withrespect to the illustrated embodiments, it will be understood that theinvention is capable of modification and variation and is limited onlyby the following claims.

What is claimed is:
 1. In combination, an electric valve and hydraulicmanifold assembly for controlling de-actuation of combustion chambervalves in a multi-cylinder engine comprising: (a) a deckplate having (i)a supply pressure inlet port and a supply channel communicatingtherewith and formed on a common side of the deckplate; (ii) a pluralityof control pressure inlet ports disposed in spaced arrangement on thecommon side of said deckplate; (iii) a plurality of control pressureoutlet ports, on the common side of the deckplate, with each of thecontrol pressure outlet ports communicating respectively with one ofsaid control pressure inlet ports; (b) a gasket disposed on said commonside of said deckplate and having a plurality of spaced valve inletports communicating with said supply channel, and a plurality of spacedtransfer ports each communicating respectively with one of said controlpressure inlet ports in said deckplate and a pair of ports communicatingwith and dividing each of said control pressure outlet ports into anintake and an exhaust valve control pressure port, said gasket havingintegrally formed therewith a plurality of valve mounting bosses, witheach boss having a valving cavity therein communicating with one of saidvalve inlet ports and each of said cavities communicating with one ofsaid transfer ports respectively; (c) an electrically operated valvedisposed in each of said valving cavities and operable upon electricalenergization to provide fluid communication between said inlet channeland said transfer port; (d) means operable for retaining the valve ineach of said valving cavities, and for retaining and sealing said gasketover the control pressure outlet ports, the supply channel, and saidsupply pressure inlet ports; and, (e) means for providing electricalconnection to the valve in each of said valving cavities.
 2. Thecombination defined in claim 1, wherein said means for retaining saidvalves in each of said cavities includes a common plate received overeach valve.
 3. The combination defined in claim 2, wherein said meansfor retaining and sealing said gasket over the control pressure outletports, the supply channel and the supply pressure inlet ports includes apair of superposed plates.
 4. The combination defined in claim 1,wherein said gasket is formed with polyamide material having aboutone-third by volume of glass filler.
 5. The combination defined in claim1, wherein said deckplate is formed of aluminum material.
 6. Thecombination defined in claim 1, wherein said deckplate includes a bossdisposed on the side opposite said common side for mounting a pressuresensor.
 7. The combination defined in claim 1, wherein said gasketincludes portions thereof arranged to seal about the margins of saiddeckplate upon mounting on the engine.
 8. The combination defined inclaim 1, wherein said means for providing electrical connection for saidvalve in each of said cavities includes a common lead frame includingterminals effecting electrical connection with the valve in each cavity.9. The combination defined in claim 8, wherein said terminals effectplug-in electrical connection with the valve in each of said cavities.10. The combination defined in claim 1, wherein said terminals includeelectrical leads for external electrical connection thereto.
 11. Thecombination defined in claim 1, wherein said valve includes a means forsealing said valve in said cavity and isolating said transfer port fromsaid control pressure inlet port.
 12. The combination defined in claim11, wherein said means for sealing comprises a pair of annular seals.13. The combination defined in claim 1, wherein said valve is solenoidoperated.
 14. The combination defined i claim 1, wherein said means forretaining the valve and said gasket comprises a pair of superposedplates attached to the deckplate.
 15. A method of making anelectro-hydraulic assembly for controlling actuation of combustionchamber valves in a multi-cylinder engine comprising: (a) providing adeckplate and forming a supply channel on one side thereof and an inletsupply pressure port communicating therewith; (b) forming a plurality ofcontrol pressure inlet ports in spaced arrangement on the one side ofthe deckplate and forming a plurality of control pressure outlet portsin said one side each communicating respectively with one of saidcontrol pressure inlet ports; (c) disposing a one-piece gasket on saidone side of the deckplate and forming separate intake and exhaust valvepressure control ports therein communicating with a common one of thecontrol pressure outlet ports in the deckplate and forming a pluralityof spaced supply ports therein with each supply port communicating withthe deckplate supply channel; (d) forming a plurality of valve mountingbosses spaced on said gasket and forming a valving cavity in each bossand disposing a valve in each of said cavities for communicating withone of the gasket supply ports and forming a transfer passage in eachcavity and communicating the transfer passage respectively with one ofthe control pressure inlet ports in the deckplate; (e) disposing aninlet and outlet of an electrically operated valve in each of saidcavities and communicating the valve inlet with said supply port thereinand the valve outlet with said transfer port therein; and, (f)compressing said gasket on said deckplate and sealing over said supplychannel, said control pressure inlet ports and said control pressureoutlet ports and retaining said valves on said bosses and electricallyconnecting to each of the valves.
 16. The method defined in claim 15,wherein the step of disposing the inlet and outlet of a valve includesdisposing an annular seal in said cavity.
 17. The method defined inclaim 15, wherein the step of retaining said valves includes disposing aplurality of spacers between the lead frame and the gasket.
 18. Themethod defined in claim 18, wherein the step of retaining said valvesincludes disposing a fastener through each of the spacers.
 19. Themethod defined in claim 15, wherein the step of disposing a one-piecegasket includes forming a gasket having polyamide material therein. 20.The method defined in claim 15, wherein the step of forming a gasketincludes forming a gasket having polyamide material filled aboutone-third by volume with glass material.
 21. The method defined in claim15, wherein the step of providing a deckplate includes forming a boss onthe side opposite said one side and disposing a pressure sensor in saidboss.
 22. The method defined in claim 15, wherein the step ofelectrically connecting to each of the valves includes plug-inconnecting.